BY ORDER OF THE SECRETARY OF THE AIR FORCE AIR FORCE INSTRUCTION 91-202 24 ...

215 Pages·2016·1.48 MB·English

AIR FORCE INSTRUCTION 91-202
BY ORDER OF THE
SECRETARY OF THE AIR FORCE
12 MARCH 2020
AIR FORCE RESERVE COMMAND
Supplement
05 JANUARY 2021
CORRECTIVE ACTION 06 JANUARY 2021

Safety
THE US AIR FORCE MISHAP
PREVENTION PROGRAM
COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for on the e-Publishing website at
www.e-Publishing.af.mil downloading or ordering.
RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AFSEC/SEG Certified by: AFSEC/CV
(Colonel William Culver)
Supersedes: AFI 91-202, 24 June 2015; Pages: 215
AFI 91-217, 11 April 2014
(AFRC)
OPR: HQ AFRC/SEF/SEG/SEW Certified by: HQ AFRC/SE
(Colonel John Lesho)
Supersedes: AFI 91-202_AFRCSUP, Pages: 10
24 July 2016

This instruction implements Air Force Policy Directive (AFPD) 91-2, Safety Programs, relevant
safety portions of Department of Defense Directive (DoDD) 3100.10, Space Policy, DoD
Instruction (DoDI) 3100.12, Space Support, DoDI 3200.18, Management and Operation of the
Major Range and Test Facility Base, and the Memorandum of Agreement between the Department
of the Air Force and the Federal Aviation Administration on Safety for Space Transportation and
Range Activities. This instruction implements North Atlantic Treaty Organization (NATO)
Standardization Agreements (STANAGs) 3101, Exchange of Flight Safety Information, and 3102,
Flight Safety Cooperation in Common Ground/Air Space. It establishes mishap prevention
program requirements, assigns responsibilities for program elements and contains program
management information. It applies to all Regular Air Force, Air Force Reserve and Air National
2 AFI91-202_AFRCSUP 05 JANUARY 2021
Guard (ANG) military and civilian personnel. For the purposes of this instruction, ANG and Air
Force Reserve Command (AFRC) are included in all references to Major Commands
(MAJCOMs). At joint bases, Air Force units will follow the requirements in this instruction, along
with guidance contained within inter-service and/or inter-agency agreements. At enduring and
contingency locations outside the United States, follow the requirements in this instruction so long
as they do not conflict with applicable requirements from any of the following: host nation
requirements made applicable by international agreement, Overseas Environmental Baseline
Guidance Document standards, country-specific Final Governing Standards, Geographic
Combatant Command policy, environmental annex to operational order, operational plan
(OPLAN) or other operational directive. This publication may be supplemented at any level, but
all direct Supplements must be routed to the OPR of this publication for coordination prior to
certification and approval. Send major command, field operating agency and direct reporting unit
(MAJCOM/FOA/DRU) supplements to Air Force Safety Center (AFSEC)/SE Org Box, 9700 G
Avenue, Kirtland AFB NM 87117-5670, for coordination and approval before publication. Refer
recommended changes and questions about this publication to the Office of Primary Responsibility
(OPR) using the AF Form 847, Recommendation for Change of Publication; route AF Forms 847
from the field through the appropriate functional’s chain of command. All requests for changes,
interpretations or clarifications concerning this publication must be forwarded through the
MAJCOM/FOA/DRU safety organization, who, in turn, as applicable, will forward to AFSEC.
The authorities to waive wing/unitlevel requirements in this publication are identified with a Tier
(“T-0, T-1, T-2, T-3) number following the compliance statement. See AFI 33-360, Publications
and Forms Management, for a description of the authorities associated with Tier numbers. Submit
requests for waivers through the chain of command to the appropriate Tier waiver approval
authority, or alternately, to the requestor’s commander for non-tiered compliance items. Submit
waiver requests for Secretary of the Air Force, Inspector General (SAF/IG) consideration through
SAF/IGI. To meet the intent of AFI 33-360, e-mail finalized waivers (AF Form 679, Air Force
Publication Compliance Item Waiver Request/Approval) to SAF/IGI (usaf.pentagon.saf-
[email protected]). Ensure that all records created as a result of processes
prescribed in this publication are maintained in accordance with (IAW) Air Force Manual
(AFMAN) 33-363, Management of Records, and disposed of IAW Air Force Records Disposition
Schedule and disposed of IAW Air Force Records Information Management System. The use of
the name or mark of any specific manufacturer, commercial product, commodity, and/or service
in this publication does not imply endorsement by the Air Force. This Instruction requires the
collection and/or maintenance of information protected by the Privacy Act of 1974 authorized by
Title 29 United States Code (USC), Section 668, Program of Federal Agencies; Executive Order
12196, Occupational Safety and Health Programs for Federal Employees; Part 1960, Title 29,
Code of Federal Regulations (CFR), Basic Program Elements for Federal Employee Occupational
Safety and Health Programs and Related Matters; Title 5 USC § 7902, Safety Program, and DoD
Directive (DoDD) 5134.01, Under Secretary of Defense for Acquisition, Technology and Logistics
(USD(AT&L)). All records created, collected and stored under the guidance of this instruction are
subject to the provisions of the Freedom of Information Act, as authorized by Title 5 USC § 552,
Public Information; Agency Rules, Opinions, Orders, Records, and Proceedings, and IAW DoDM
5400.07_AFMAN 33-302, Freedom of Information Act Program. The System of Records Notice
F036 AF PC Q, Personnel Data System (PDS); F024 AF IL C Motor Vehicle Operator’s Records,
and F032 AF ILE, Enterprise Environmental, Safety and Occupational Health-Management
AFI91-202_AFRCSUP 05 JANUARY 2021 3
Information System (EESOH-MIS) are available at:
https://dpcld.defense.gov/privacy/SORNS.aspx.
(AFRC) This supplement implements and extends the guidance of AFI 91-202, The US Air Force
Mishap Prevention Program. This publication does not apply to the Air National Guard (ANG)
unless specifically outlined in the appropriate support agreement. This AFI may be supplemented
at any level, but all supplements must be routed to AFRC/SE for coordination prior to certification
and approval. Refer recommended changes and questions about this publication to the Office of
Primary Responsibility (OPR) using the AF Form 847, Recommendation for Change of
Publication; route AF Form 847s through AFRC/SE. Ensure that all records created as a result of
processes prescribed in this publication are maintained IAW Air Force Instruction (AFI) 33-322,
Records Management and Information Governance Program, and disposed of IAW Air Force
Records Information Management System (AFRIMS) Records Disposition Schedule (RDS). The
authorities to waive wing/unit level requirements in this publication are identified with a Tier (“T-
0, T-1, T-2, T-3”) number following the compliance statement. See DAFI 33-360, Publications
and Forms Management, for a description of the authorities associated with the Tier numbers.
Submit requests for waivers through the chain of command to the appropriate Tier waiver approval
authority, or alternately, to the requestor’s commander for non-tiered compliance items. The use
of the name or mark of any specific manufacturer, commercial product, commodity or service in
this publication does not imply endorsement by the Air Force.
SUMMARY OF CHANGES
This document is substantially revised and must be completely reviewed. This revision clarifies
requirements of the mishap prevention program as framed within the Air Force Safety
Management System. Chapter 12, Hazard Abatement, was consolidated with Chapter 4, Hazard
Identification and Reporting, and renamed Chapter 4, Hazard Identification, Reporting and
Abatement. Chapter 12, Contract Safety, was added to give Air Force safety professionals more
insight on the contract safety process. Chapter 10, Space Safety, incorporates substantial changes.
Chapter 1, Program Overview, Chapter 2, Safety Organization, and Chapter 11, System Safety
and Safety Risk Assessments, have changes regarding space safety and/or space systems. Program
management questions have been added at the end of each chapter to assist managers and
supervisors in managing their programs. Attachments have been incorporated in the body of the
instruction and now reside in Chapter 13, Supporting Guidance, Chapter 14, Safety Training,
and Chapter 15, Miscellaneous Safety Information.
(AFRC) This document has been substantially revised and needs to be completely reviewed.
Major changes include: Chapter 1, Program Overview and Responsibilities, directed the use of
MICT communicator. Chapter 2, Safety Organization, to ensure hyperlinks to suitable electronic
medium are accessible and requirements for FSNCOs. Chapter 3, Safety Assurance, Non-
supported groups with an assigned safety staff will be evaluated by qualified safety personnel.
Chapter 7, Aviation Safety, minor changes for program management. Chapter 8, Occupational
Safety, host and tenant occupational safety managers will incorporate a comprehensive assessment
as outlined in the AFRC Assessment Writing Guide and minor changes for program management
and oversight. Chapter 9, Weapons Safety, minor changes to enhance program management.
4 AFI91-202_AFRCSUP 05 JANUARY 2021
Chapter 1—PROGRAM OVERVIEW AND RESPONSIBILITIES 11
1.1. Purpose. .................................................................................................................. 11
1.2. Vision. .................................................................................................................... 11
1.3. The Air Force Mishap Prevention Program. .......................................................... 11
1.4. Mishap Prevention Program Disciplines (Aviation, Occupational, Weapons,
Space, etc.). ............................................................................................................. 11
1.5. Air Force Occupational Safety and Health (AFOSH) Guidance and Applying
Standards. ................................................................................................................ 12
1.6. Roles and Responsibilities. ..................................................................................... 15
1.7. Waivers. .................................................................................................................. 51
1.8. Military-Unique and Nonmilitary-Unique Policy. ................................................. 51
Chapter 2—SAFETY ORGANIZATION 53
2.1. Safety Staff. ........................................................................................................... 53
2.2. Unit Safety Representative (USR). ........................................................................ 59
2.3. Safety Education/Training. .................................................................................... 60
2.4. Safety Office Vehicles and Equipment. ................................................................. 61
2.5. Safety Library. ....................................................................................................... 61
2.6. Environment, Safety and Occupational Health Councils (ESOHC). ..................... 61
2.6. (AFRC) Environment, Safety and Occupational Health Councils (ESOHC). ....... 61
2.7. Non-USAF Councils and Committees. .................................................................. 62
2.8. Major Range and Test Facility Base (MRTFB) Safety Programs. ........................ 62
Chapter 3—SAFETY ASSURANCE 64
3.1. General. .................................................................................................................. 64
Table 3.1. Safety Evaluations, Assessments and Inspections. ................................................. 64
3.2. Safety Evaluations. ................................................................................................ 65
3.3. Safety Program Evaluation (SPE). ......................................................................... 65
3.3. (AFRC) Safety Program Evaluation (SPE). ........................................................... 65
3.4. Safety Program Assessments. ................................................................................ 65
3.5. Annual Program Management Review (APMR). .................................................. 67
AFI91-202_AFRCSUP 05 JANUARY 2021 5
3.6. Annual Safety Inspections. .................................................................................... 68
3.7. Spot Inspections. .................................................................................................... 70
3.8. High Interest Areas. ............................................................................................... 71
3.9. Administrative Areas. ............................................................................................ 71
3.10. Special and Seasonal Inspections. .......................................................................... 72
3.11. Staff Assistance Visits (SAV). ............................................................................... 72
3.11. (AFRC) Staff Assistance Visits (SAV). ................................................................. 72
3.12. Federal/State Inspections and Investigations. ........................................................ 73
3.13. Contract Performance Assessment. ....................................................................... 73
Chapter 4—HAZARD IDENTIFICATION, REPORTING AND ABATEMENT 74
4.1. Hazard Identification. ............................................................................................ 74
4.2. Reporting Criteria. ................................................................................................. 74
4.3. Hazard Reporting System. ..................................................................................... 74
4.4. Additional Reporting Procedures. .......................................................................... 75
4.5. Air Force Form 457, Airmen Appeal Procedures. ................................................. 76
4.6. Risk Reduction and Mitigation. ............................................................................. 76
4.7. Preparation of Risk Assessments. .......................................................................... 76
4.8. Hazard Abatement. ................................................................................................ 77
4.9. Hazard Control Hierarchy. ..................................................................................... 77
4.10. Hazard Abatement Requirements. ......................................................................... 77
4.11. Critical/Imminent Danger Situations. .................................................................... 78
4.12. Posting Notification of Hazards. ............................................................................ 78
4.13. Installation Master Hazard Abatement Plan (MHAP). .......................................... 79
4.14. Funding for Hazard Abatement. ............................................................................ 80
4.15. End of Year Annual Master Hazard Abatement Survey and Facility/Workplace
Inspection Report. ................................................................................................... 80
Chapter 5—INFORMATION AND DATA ANALYSIS 82
5.1. Information Protection. .......................................................................................... 82
5.1. (AFRC) Information Protection. ............................................................................ 82
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5.2. Recurring Publications. .......................................................................................... 82
5.3. Methods of Information Distribution. .................................................................... 82
5.4. Mishap Analysis Program. ..................................................................................... 83
5.5. Mishap Prevention Analysis Methods. .................................................................. 83
5.6. Use of Analyzed Data. ........................................................................................... 84
5.7. Air Force Combined Mishap Reduction System. .................................................. 84
5.8. Organizational Safety Assessment (OSA). ............................................................ 85
5.9. Military Flight Operations Quality Assurance (MFOQA). .................................... 85
5.10. Airman Safety Action Program (ASAP). ............................................................... 85
5.11. Line Operations Safety Audit. ............................................................................... 86
5.12. Standard Mishap Metrics. ...................................................................................... 86
5.13. Calculating Federal Employee Compensation Metric (Rate). ............................... 87
5.14. AFSAS Analysis and Query Tools. ........................................................................ 88
Chapter 6—DEPLOYMENT AND CONTINGENCY SAFETY 89
6.1. Deployment and Contingency Safety Program. ..................................................... 89
6.2. Air Force Forces Chief of Safety (AFFOR/SE). ..................................................... 89
6.3. AFFOR Deployed Unit Safety Functions and Organizations. ............................... 90
6.4. Mishap Prevention Program. ................................................................................. 93
6.5. Monthly, Quarterly and Annual Safety Awards. ................................................... 93
6.6. AFFOR/SE Visits. ................................................................................................. 93
Chapter 7—AVIATION SAFETY 95
7.1. Program Management. ........................................................................................... 95
7.1. (AFRC) Program Management. ............................................................................. 95
7.2. Plans. ...................................................................................................................... 96
7.3. Programs. ............................................................................................................... 96
7.4. Aero Club Operations. ........................................................................................... 99
7.5. Training Meetings and Briefings. .......................................................................... 100
7.5. (AFRC) Training Meetings and Briefings. ............................................................ 100
7.6. Inspections/Assessments and Monitoring. .............................................................. 101
AFI91-202_AFRCSUP 05 JANUARY 2021 7
7.7. Airfield Maintenance, Construction and Waivers (Installation). ........................... 102
7.7. Airfield Maintenance and Construction and Waivers (Installation). ..................... 103
Chapter 8—OCCUPATIONAL SAFETY 104
8.1. Program Management. ........................................................................................... 104
8.2. Assurance Requirements. ....................................................................................... 104
8.3. Installation Occupational Safety Staff Responsibilities. ........................................ 104
8.4. Tenant Unit and Geographically Separated Unit Responsibilities. ........................ 107
8.5. Unit Safety Representative (USR) Responsibilities. .............................................. 108
8.6. Hazard Identification and Abatement. ................................................................... 108
8.7. Federal/State Inspections of DoD Working Conditions and Mishap
Investigations. ......................................................................................................... 108
8.8. DoL Occupational Safety and Health Administration Annual Visit Summary. .... 109
8.9. Occupational Safety Corporate Committee. .......................................................... 109
Chapter 9—WEAPONS SAFETY 110
9.1. Program Management. ........................................................................................... 110
9.2. Weapons Safety Personnel Management and Manning Plan. ................................ 110
9.3. Explosives Safety Standards. ................................................................................. 110
9.4. Weapons Safety Personnel. .................................................................................... 110
9.4. (AFRC) Weapons Safety Personnel. ...................................................................... 111
9.5. Weapons Safety Program Requirements. .............................................................. 113
9.6. Missile Safety. ....................................................................................................... 113
9.7. Nuclear Surety. ...................................................................................................... 113
9.8. Unit Directed Energy Safety Program Functions. ................................................. 113
9.9. Munitions Rapid Response Team. ......................................................................... 114
9.10. Department of Defense Explosives Safety Board (DDESB). ................................ 114
9.11. Weapons, Explosives and DEW Training............................................................... 114
9.12. Weapons Safety Committees. ................................................................................ 116
9.13. (AFRC) ADWSR Responsibilities. ....................................................................... 116
9.14. (AFRC) Training. ................................................................................................... 116
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9.15. (AFRC) Weapons Safety Program Inspection/Assessment Scope. ....................... 116
9.16. (AFRC) Spot Inspections. ...................................................................................... 117
Chapter 10—SPACE SAFETY 118
10.1. Program Management. ........................................................................................... 118
10.2. Space Safety Responsibilities. ............................................................................... 118
10.3. Space Safety Council (SSC). ................................................................................. 119
10.4. Space Nuclear Safety. ............................................................................................ 120
10.5. Ground Based Space System Safety. ...................................................................... 120
10.6. Pre-Launch. ............................................................................................................ 120
10.7. Launch Safety. ........................................................................................................ 121
10.8. Orbital Safety. ......................................................................................................... 124
Chapter 11—SYSTEM SAFETY & SAFETY RISK ASSESSMENTS 132
11.1. Overview. ............................................................................................................... 132
11.2. System Safety Applied to Acquisition Activities. .................................................. 133
11.3. System Safety Risk Acceptance Process ................................................................ 134
11.4. System Safety Groups (SSG). ................................................................................ 135
11.5. Non-Developmental Items. .................................................................................... 137
11.6. System Safety Engineering Analysis (SSEA). ....................................................... 137
11.7. Application of a Safety Risk Assessment (SRA). ................................................... 137
11.8. Safety Risk Assessment Purpose and Risk Decision Authority Empowerment. .... 138
11.9. Core Safety Risk Assessment Principles. .............................................................. 139
11.10. Safety Office SRA Reviews. .................................................................................. 141
Chapter 12—CONTRACT SAFETY 143
12.1. Contract Safety Program. ....................................................................................... 143
12.2. Contract Types. ...................................................................................................... 143
Table 12.1. Contract Considerations. ......................................................................................... 143
12.3. Contractor Compliance. ......................................................................................... 144
12.4. Safety Office. ......................................................................................................... 144
AFI91-202_AFRCSUP 05 JANUARY 2021 9
Chapter 13—SUPPORTING GUIDANCE 146
13.1. Air Force Safety Management System (AFSMS). .................................................. 146
Figure 13.1. AFSMS Pillars. ....................................................................................................... 146
Figure 13.2. AFSMS Framework. ............................................................................................... 147
Figure 13.3. The Air Force 5-Step RM Process. ......................................................................... 148
13.2. Annual Program Management Review (APMR). ................................................... 151
13.3. Federal/State Inspections of DoD Working Conditions and Mishap
Investigations. ......................................................................................................... 152
13.4. USAF Aviation Safety Equipment Database Reporting. ........................................ 156
13.5. Mishap Response. ................................................................................................... 157
13.6. Job Hazard Analysis (JHA). ................................................................................... 158
13.7. Risk Assessment Codes (RAC). ............................................................................. 159
Table 13.1. Safety and Ergonomic Hazard Risk Assessment Code Matrix. .............................. 160
13.8. Abatement Priority Number (APN). ....................................................................... 160
Table 13.2. Severity and Probability Multiplier Matrix. ............................................................ 161
Table 13.3. Abatement Priority Number Index. ......................................................................... 162
13.9. Preparation of Safety Risk Assessments. ............................................................... 162
Figure 13.4. Sample Risk Assessment Layout and Guidance. .................................................... 162
13.10. Safety Release. ........................................................................................................ 163
Figure 13.5. Safety Release Letter (Example). ........................................................................... 164
13.11. Launch Vehicle Space Debris Assessment Report (SDAR). .................................. 164
Table 13.4. SDAR Format. ........................................................................................................ 165
13.12. Combined Space Vehicle Space Debris Assessment Report/End-of-Life Plan
(SDAR/EOLP). ........................................................................................................ 168
Table 13.5. Contents of SDAR/EOLP. ...................................................................................... 169
Chapter 14—SAFETY TRAINING 173
14.1. Job Safety Training Outline. ................................................................................... 173
14.2. Continuing Education and Training Courses. ......................................................... 177
Table 14.1. Continuing Career Safety Professional Development (Recommended Safety
Courses). .................................................................................................................. 177
10 AFI91-202_AFRCSUP 05 JANUARY 2021
Table 14.2. Continuing Career Safety Professional Development (AFSEC Courses Awarding
Continuing Education Units). .................................................................................. 178
14.3. Safety Education and Training. .............................................................................. 178
Table 14.3. Mishap Investigation. .............................................................................................. 178
Table 14.4. Unit Safety Representative (USR). ......................................................................... 178
Table 14.5. Aviation. ................................................................................................................. 179
Table 14.6. Occupational. .......................................................................................................... 179
Table 14.7. Weapons.................................................................................................................. 179
Table 14.8. Space. ...................................................................................................................... 179
Table 14.9. System Safety. ........................................................................................................ 180
Table 14.10. Management. ........................................................................................................... 180
Table 14.11. Risk Management (RM). ........................................................................................ 180
Table 14.12. Other. ...................................................................................................................... 180
14.4. 1S0X1 Retrainee Evaluation Process. .................................................................... 180
Figure 14.1. 1S0 Safety Retraining Memorandum (Example). ................................................... 182
14.5. Supervisor Safety Training. ................................................................................... 182
Chapter 15—MISCELLANEOUS SAFETY INFORMATION 184
15.1. Instructions for Completing AF Form 1118, Notice of Hazard. ............................. 184
15.2. Instructions for Completing AF Form 3, Hazard Abatement Plan. ........................ 184
15.3. Pre-Departure Travel Safety (Examples Only). ..................................................... 187
15.4. Air Force Off-Duty High-Risk Activities Program. .............................................. 188
Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 190